Winch problems

rob_90 · Feb 9, 2014

Hi all i have a 12500 tmax winch yesterday when offroading i got stuck so i used my front winch attached it on to my pals defender i used the winch to winch me halfway out then my pal just towed me the rest only 10 yards when i unhooked the winch my winch will now not come in out out it sounds as if its still working but nothings turning. The clutch is in the engaged position bit nothing any ideas. ??

Pumpy · Feb 9, 2014

Sounds like you may not have been pulling in a straight line, this can force the drum into the drive gear, there is a circlip holding the drive gear in place, and a retaining ring over the circlip, the retaining ring can get mashed as the drum is forced into it, so the drive gear floats back into the drum and disengages from the gearbox main gear, the motor will still turn but it acts as if it's disengage.

Spares are easy to source, split it between the drum/gearbox and you'll see the drive gear retaining ring, check the seals while you're at it, not expensive. There are exploded pics if you Google it.

here's one I mashed earlier :lol: pic shows drive gear with circlip on, mashed retaining ring, and two plastic bearings (might be worth renewing while you've got it in bits)

rob_90 · Feb 9, 2014

Yeah i pulled it on a angle is this an easy job for an amatuer?

Pumpy · Feb 9, 2014

Yes mate, getting it off the truck is more of a ball ache than fixing it :lol:

take off the fair-lead, remove the tie bars (22) and pull it apart, careful not to lose the rollers which sit in the grooves of the brake assy(11) inside the drum which might fall out (sit them back in the grooves to reassemble), you'll see the floating gear (7) at the gearbox end, and the mashed retaining ring (8) usually held on by two small +drive screws to the main gear, it'll have pulled through those screws leaving them still in the main gear.

Now you could just replace the retaining ring and pop it back together, but depending how old/how much abuse it's had, you might want to change the nylon bearings (21) too. I did the bearings, retaining ring, and got new boots/covers for the electrical connectors (that had melted) for about £20.

If it's really minging inside you might want to take the flanges off the motor or gearbox to clean inside, if so you'll need new paper gaskets too to reassemble it, mine was spotless inside.

If you pull at an angle all the rope bunches up at one end, this forces the drum into the retaining ring (as you found!)

rob_90 · Feb 9, 2014

That sounds too tech for me bud would you be interested in doing it for me i would pay of course?

warrior · Feb 9, 2014

rob_90 said:
That sounds too tech for me bud would you be interested in doing it for me i would pay of course?

Open it up take a look, its broke so you carnt brake it, I have stripped a few now and there not that bad

Pumpy · Feb 10, 2014

rob_90 said:
That sounds too tech for me bud would you be interested in doing it for me i would pay of course?

Seriously mate, once you've got it off the truck and removed the fair-lead, it's two bolts on the tie bars to split it, and two screws on the retaining ring, don't be put off by the exploded view, all that gubbins stays put.

I'm near J11 A14, like an hour+ drive from Brum, I'd do it for nowt if you've got the parts mate, but it'd cost you a bomb in Juice

rob_90 · Feb 10, 2014

Ok will give it a shot will let ya know

darrenaroberts · Jan 14, 2015

Hi Pumpy,

Where abouts did you get your spares from?

chers

Darren

Pumpy said:
Yes mate, getting it off the truck is more of a ball ache than fixing it :lol:

take off the fair-lead, remove the tie bars (22) and pull it apart, careful not to lose the rollers which sit in the grooves of the brake assy(11) inside the drum which might fall out (sit them back in the grooves to reassemble), you'll see the floating gear (7) at the gearbox end, and the mashed retaining ring (8) usually held on by two small +drive screws to the main gear, it'll have pulled through those screws leaving them still in the main gear.

Now you could just replace the retaining ring and pop it back together, but depending how old/how much abuse it's had, you might want to change the nylon bearings (21) too. I did the bearings, retaining ring, and got new boots/covers for the electrical connectors (that had melted) for about £20.

If it's really minging inside you might want to take the flanges off the motor or gearbox to clean inside, if so you'll need new paper gaskets too to reassemble it, mine was spotless inside.

If you pull at an angle all the rope bunches up at one end, this forces the drum into the retaining ring (as you found!)

IamRobbie · Jan 14, 2015

take it apart, take pics. put it back together by using pics..

after re-assembly discard any spare nuts and bolts that should be inside the winch.

winchman · Jan 15, 2015

I agree take it to bits but if you are not sure of your DIY skill its best left alone as I have seen so many damaged as people didn't have a clue but had a go.
If you take loads of photos that's a good help

Pumpy · Jan 15, 2015

darrenaroberts said:
Hi Pumpy,

Where abouts did you get your spares from?

chers

Darren

Got mine from 12V Winches - Winchmax but they only do their own winches, I think Bearmach stocks t-max parts

darrenaroberts · Jan 16, 2015

Pumpy said:
Got mine from 12V Winches - Winchmax but they only do their own winches, I think Bearmach stocks t-max parts

thanks....

Winch problems

rob_90

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Pumpy

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rob_90

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rob_90

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warrior

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rob_90

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darrenaroberts

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winchman

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